Lean Six Sigma Yellow Belt Certification The Improve Phase 2 — Questions and Answers
Question 1: A team uses a Pugh Concept Selection Matrix to evaluate solutions. What is the primary purpose of this tool?
- To document root causes of defects
- To compare multiple solution alternatives against weighted criteria (Correct answer)
- To map the current state value stream
- To calculate process sigma levels
Correct answer: To compare multiple solution alternatives against weighted criteria
The Pugh matrix scores competing solutions against evaluation criteria, helping teams select the best option objectively.
Question 2: During a kaizen event, the team identifies a process step that adds no value. According to Lean principles, what should they do first?
- Automate the step to reduce cost
- Eliminate the step if possible (Correct answer)
- Move the step to a different department
- Add a control chart to monitor the step
Correct answer: Eliminate the step if possible
Lean's first priority is to eliminate non-value-added steps entirely before considering optimization or automation.
Question 3: A solution pilot is run on one production line before full rollout. What does the pilot primarily validate?
- That the root cause was correctly identified
- That the solution is feasible and achieves the desired improvement (Correct answer)
- That the control plan is complete
- That all stakeholders have signed off
Correct answer: That the solution is feasible and achieves the desired improvement
A pilot tests solution feasibility and effectiveness at small scale before committing to full implementation.
Question 4: Which improvement tool is best suited for reducing changeover time between product runs?
- FMEA
- SMED (Single-Minute Exchange of Die) (Correct answer)
- Regression analysis
- Box-and-whisker plot
Correct answer: SMED (Single-Minute Exchange of Die)
SMED is a Lean technique specifically designed to reduce equipment changeover and setup times.
Question 5: A process improvement reduces average cycle time from 12 minutes to 8 minutes. What is the percentage improvement?
- 25%
- 33% (Correct answer)
- 50%
- 67%
Correct answer: 33%
The reduction is 4 minutes from a baseline of 12 minutes: (4/12) × 100 = 33.3% improvement.
Question 6: In the Improve phase, what is the purpose of a risk assessment before implementing a solution?
- To identify which employees resist the change
- To anticipate potential failure modes and plan mitigation actions (Correct answer)
- To calculate the return on investment
- To update the project charter
Correct answer: To anticipate potential failure modes and plan mitigation actions
Risk assessment (often via FMEA) identifies what could go wrong with the solution so mitigation plans can be prepared in advance.
Question 7: A team implements 5S in a work area. Which step involves keeping the work area clean and identifying problems through cleanliness?
- Sort
- Set in Order
- Shine (Correct answer)
- Standardize
Correct answer: Shine
Shine (the third S) focuses on cleaning the work area and using cleanliness to expose abnormal conditions like leaks or damage.
Lean Six Sigma Yellow Belt Certification The Improve Phase 2
A team uses a Pugh Concept Selection Matrix to evaluate solutions.
What is the primary purpose of this tool?